Heat Exchanger Plates with Integral Bypass Blocking Tabs

ABSTRACT

A heat exchanger containing a plurality of spaced-apart plate pairs, where each plate pair defines a flow passage for the flow of a first fluid. In addition, one or more fins are thermally coupled and sandwiched by the spaced-apart plate pairs for flow of a second fluid. And, a fluid manifold that is fluidly coupled to the spaced-apart plate pairs at a manifold end of the spaced-apart plate pairs is provided. Further, a tab that extends from a flange end of a first plate of the first plate pair and in contact with a second tab extending from a flange end of a second plate of a second plate pair for providing a fluid flow blocker. Also, provided is a heat exchanger assembly containing a housing and the heat exchanger described herein.

FIELD

The specification relates to a heat exchanger having an air bypassblocking tabs, and a heat exchanger assembly having a housing and theheat exchanger described herein.

BACKGROUND

Charge air cooler heat exchangers are well known in the art for mountingalong the flow path of charge air supplied to a combustion engine. Thischarge air typically comprises ambient air which has been compressed byapparatus such as a supercharger or turbocharger to provide an increasedmass flow of air to the engine to permit the engine to combust increasedquantities of fuel and thereby operate at an increased level of powerand performance. However, compression of ambient air also elevates theair temperature such that the charge air has a relatively hightemperature which, if not reduced, undesirably increases total engineheat load. It is therefore desirable to cool the charge air prior tosupply thereof to the engine, and charge air coolers are provided forthis purpose.

In general, the charge air cooler is constructed from a plurality oflightweight heat transfer elements of a heat conductive material, suchas copper or aluminum, shaped to provide extended heat transfer surfacesand defining a flow path for the charge air in heat transfer relationwith a suitable coolant, such as ambient air or a liquid coolant. Morespecifically, the charge air cooler may be constructed from a network offinned tubes such that charge air flowing over the fins is associatedwith a coolant flowing through the tubes resulting in adequate heattransfer for some engine system applications. Alternatively, whenimproved heat transfer capacity is required, the charge air cooler isconstructed from a stacked array of plates and fins which cooperate todefine a heat exchanger core having separate flow paths for passage ofthe charge air and the coolant in close heat transfer, relation witheach other. In either case, however, the charge air cooler is desirablymounted directly into the intake manifold of the engine wherein chargeair passing through the intake manifold is reduced in temperature byflow through the charge air cooler immediately prior to ingestion by theengine.

The current heat exchanger products can allow air bypass past the endsof the fins (the plate lap joints extend beyond the end of the fins, orextend beyond the liquid fluid manifold, leaving unintended air bypasschannels), or require additional brazed on components to compensate byblocking off these regions, which adds significant cost and/or may beimpossible for certain cooler configurations. To address the aboveproblem, wide elastomer seals can be provided, such as adhesively bondedor mechanically trapped seals, as part of the ducting installation—tominimize such bypass. But these seal materials are expensive, addassembly complexity, and have service durability limitations.

Another compensating alternative is to overdesign the heat exchanger,either by over-sizing or adding much higher fin density (pressure droppenalty) so that performance is maintained even with bypass flow, whichcan have other disadvantages.

There is a need in the art for a heat exchanger and a heat exchangerassembly, where the heat exchanger can reduce or prevent air bypassaround the ends of the heat exchanger.

SUMMARY OF THE INVENTION

In one aspect, the specification discloses a heat exchanger, containing:

a plurality of spaced-apart plate pairs, where each plate pair defines aflow passage for the flow of a first fluid;

one or more fins thermally coupled and sandwiched by the spaced-apartplate pairs for flow of a second fluid;

a fluid manifold being fluidly coupled to the spaced-apart plate pairsat a manifold end of the spaced-apart plate pairs; and

a tab extending from a flange end of a first plate of a first plate pairand being in contact with a second tab extending from a flange end of asecond plate of a second plate pair for providing a fluid flow blocker.

In another aspect, the specification discloses a heat exchangercontaining

a plurality of spaced-apart plate pairs, where each plate pair defines aflow passage for the flow of a first fluid;

one or more fins thermally coupled and sandwiched by the spaced-apartplate pairs for flow of a second fluid;

a fluid manifold being fluidly coupled to the spaced-apart plate pairsat a manifold end of the spaced-apart plate pairs; and

a tab extending from a flange end of a first plate of the first platepair and being in contact with a second plate of a second plate pair forproviding a fluid flow blocker.

In a further aspect, the specification discloses a heat exchangerassembly containing

a housing having a cavity in communication with an opening; and

a heat exchanger, as described herein, receivable in the cavity of thehousing.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made, by way of example, to the accompanyingdrawings which show example embodiments of the present application, andin which:

FIG. 1 shows an air intake manifold for receiving a heat exchanger inaccordance with an embodiment of the specification;

FIG. 2 shows a front elevational view of a heat exchanger in accordancewith a first embodiment of the specification;

FIG. 3 shows a side elevational view of a heat exchanger in accordancewith a first embodiment of the specification;

FIG. 4 shows a perspective view of an expanded portion of the heatexchanger in accordance with a first embodiment of the specification;

FIG. 5 shows a perspective view of an expanded portion of a single plateof a plate pair in accordance with a first embodiment of thespecification;

FIG. 6 shows a perspective view of an expanded portion of a single plateof a plate pair in accordance with a second embodiment of thespecification;

FIG. 7 shows a perspective view of an expanded portion of a single plateof a plate pair in accordance with a third embodiment of thespecification; and

FIG. 8 shows a side elevational view of an expanded portion of a platepair in accordance with a fourth embodiment of the specification.

Similar reference numerals may have been used in different figures todenote similar components.

DESCRIPTION

The specification generally relates to heat exchanger (2), such as acharge air cooler for reducing the temperature of air inflow to acombustion engine.

The heat exchanger (2) is typically placed in an air intake manifold(4), as shown in FIG. 1, which has a cavity (6) for placing the heatexchanger (2) through an opening (8). Incoming air enters the manifold(4) through an air intake aperture (10) and passes the heat exchanger(2) before being directed to the combustion engine.

The heat exchanger (2) used in accordance with the disclosure is notparticularly limited. In one example embodiment, as shown in FIGS. 2 and4, the heat exchanger (2) has a plurality of spaced-apart plate pairs(12), where each plate pair defines a flow passage for the flow of afirst fluid, such as a coolant. A fluid manifold (14) having an inlet(16) and outlet (18) (FIGS. 2 and 3) is also provided; where the fluidmanifold (14) is connected to the flow passage of each plate pair (12)to allow fluid, such as the coolant, to enter through the inlet (16)pass through the flow passages of the plate pairs (12) and exit throughthe outlet (18). The position of the fluid manifold (14) and the inlet(16) and outlet (18) are not particularly limited. In one embodiment, asshown in FIGS. 2 and 3, the inlet and outlet can be present on a topplate (20). While in another embodiment (not shown), the inlet (16) andoutlet (18) can be present on a side face (22) of the heat exchanger(2).

The space between each spaced-apart plate pair (12) is provided with afin (24). The fins (24) can provide for a second fluid flow passage,generally the air entering through the air intake aperture (10); andwhere the second flow passage is perpendicular to the flow passagedefined by the plate pairs (12) to allow for heat exchange.

The heat exchanger (2) as disclosed herein, has a front face (26) suchthat when the heat exchanger (2) is positioned in the air intakemanifold (4), the front face (26) is positioned at the air intakeaperture (10) and allows for the second fluid, the air, to pass throughthe fins (24) and undergo heat exchange before entering the combustionengine.

In addition, each plate of the heat exchanger (2), as disclosed herein,has a manifold end (28) and an opposing end (30), denoted herein as theflange end (30). The manifold end (28) of the heat exchanger plates havethe fluid manifold (14) coupled to the plates, while the flange end (30)have one or more tabs (32) for blocking air bypass. The heat exchanger(2), as disclosed herein, are provided with side faces (22). In theembodiment shown in FIG. 2, one of the side faces is formed by the fluidmanifold (14) while the other side face is formed by the flange ends(30) of the plate pairs (12) along with the ends of the fins (24) (FIG.4).

In the embodiment shown in FIGS. 2-5, each plate of the heat exchanger(2) is provided with a tab (32) at the flange end. The tab (32) in eachplate can be formed by creating a cut at the flange end (30) of theplates and folding up the cut section of the flange end (30), to createa face of the tab (34) (FIGS. 4 and 5) that is essentially perpendicularto the air flow direction.

The length of the tabs (32) in accordance with the specification is notparticularly limited. In the embodiments disclosed in FIGS. 2-7, thelength of the tabs (32) in each plate of the heat exchanger (2) can beset such that in the assembled heat exchanger (2), a tab (32) extendingfrom a flange end (30) of a first plate of a first plate pair is incontact with a second tab extending from a second plate of a second (oradjacent) plate pair, in the heat exchanger (2). In another embodiment,as shown in FIG. 8, a tab (32) extending from the flange end (30) of afirst plate is in contact with a second plate of an adjacent (or second)plate pair. By adjusting the size and position of the tabs (32), airthat bypasses at the flange end (30) of the heat exchanger (2) can beblocked.

The number of tabs (32) in accordance with the specification is notparticularly limited. In the embodiments shown in FIGS. 2-5 and 7, eachplate of the heat exchanger (2) is provided with a single tab (32).While in the embodiment shown in FIG. 6, each plate of the heatexchanger (2) is provided with a pair of tabs (32).

The position of the tabs (32) in each plate of the heat exchanger (2) isnot particularly limited. In one embodiment in accordance with thespecification, as shown FIGS. 2-5, the tab (32) in each plate iscentrally positioned at the flange end (30) of the heat exchanger. Whilein other embodiments in accordance with the specification, and as shownin FIGS. 6-8, the tabs (32) in each plate are positioned at a corner ofthe flange end (30). When the tabs (32) are positioned near a corner ofthe flange end (30), in the assembled heat exchanger (2), the tabs (32)can be proximate to the front face (26) or back face (36) (i.e., theface away from the air intake aperture (10) of the manifold (4)),depending upon the design and other requirements.

In the embodiments shown in the figures, the tabs (32) project nearlyperpendicularly from the plates of the heat exchanger (2). However, itshould be understood that the tabs (32) can be at an angle relative tothe plane of the plates of the heat exchanger (2). Further, in theembodiments as shown in the figures, the tabs (32) can be provided witha bent neck (38) that can help with aligning of the tabs (32) inadjacent plate pairs. Alternatively, the bent neck (38) can be used forcontacting a plate of the adjacent plate pair in the heat exchanger (2).

The method of maintaining contacts between the tabs (32) or tab (32) andplate in a heat exchanger (2) is not particularly limited in accordancewith specification. In one embodiment, the tabs (32) can be contact withadjacent tabs (32) or plate of a plate pair in the heat exchanger (2).In an alternate embodiment, the tabs (32) can be brazed to tabs (32) ona plate in an adjacent plate pair or to a plate in an adjacent platepair to prevent air bypass.

In another aspect, the specification discloses a heat exchanger assemblycontaining the housing (4) and the heat exchanger (2), as describedherein. The presence of the tabs (32) in the heat exchanger (2) and theheat exchanger assembly can help to reduce the air bypass and improvethe efficiency of the heat exchange.

Certain adaptations and modifications of the described embodiments canbe made. Therefore, the above discussed embodiments are considered to beillustrative and not restrictive.

What is claimed is:
 1. A heat exchanger, comprising: a plurality ofspaced-apart plate pairs, where each plate pair defines a flow passagefor the flow of a first fluid; one or more fins thermally coupled andsandwiched by the spaced-apart plate pairs for flow of a second fluid; afluid manifold being fluidly coupled to the spaced-apart plate pairs ata manifold end of the spaced-apart plate pairs; and a tab extending froma flange end of a first plate of a first plate pair and being in contactwith a second tab extending from a flange end of a second plate of asecond plate pair for providing a fluid flow blocker.
 2. The heatexchanger according to claim 1, wherein a single tab extends from theflange end of each plate.
 3. The heat exchanger according to claim 1,wherein two or more tabs extend from the flange end of each plate. 4.The heat exchanger according to claim 1, wherein the tab is centrallypositioned at the flange end of each plate.
 5. The heat exchangeraccording to claim 1, wherein the tab is positioned at a corner of theflange end, proximate to the front face or back face of the heatexchanger.
 6. The heat exchanger according to claim 1, wherein the tabprojects nearly perpendicularly from the plates.
 7. The heat exchangeraccording to claim 1, wherein the tabs have a bent neck for aligning thetabs.
 8. The heat exchanger according to claim 1, wherein the contactingtabs are brazed together for blocking air bypass.
 9. A heat exchangerassembly, comprising: a housing having a cavity in communication with anopening; and a heat exchanger receivable in the cavity of the housing,the heat exchanger comprising: a plurality of spaced-apart plate pairs,where each plate pair defines a flow passage for the flow of a firstfluid; one or more fins thermally coupled and sandwiched by thespaced-apart plate pairs for flow of a second fluid; a fluid manifoldbeing fluidly coupled to the spaced-apart plate pairs at a manifold endof the spaced-apart plate pairs; and a tab extending from a flange endof a first plate of a first plate pair and being in contact with asecond tab extending from a flange end of a second plate of a secondplate pair for providing a fluid flow blocker.
 10. The heat exchangerassembly according to claim 9, wherein a single tab extends from theflange end of each plate.
 11. The heat exchanger assembly according toclaim 9, wherein two or more tabs extend from the flange end of eachplate.
 12. The heat exchanger assembly according to claim 9, wherein thetab is centrally positioned at the flange end of each plate.
 13. Theheat exchanger assembly according to claim 9, wherein the tab ispositioned at a corner of the flange end, proximate to the front face orback face of the heat exchanger.
 14. The heat exchanger assemblyaccording to claim 9, wherein the tab projects nearly perpendicularlyfrom the plates.
 15. The heat exchanger assembly according to claim 9,wherein the tabs have a bent neck for aligning the tabs.
 16. The heatexchanger assembly according to claim 9, wherein the contacting tabs arebrazed together for blocking air bypass.
 17. A heat exchanger,comprising: a plurality of spaced-apart plate pairs, where each platepair defines a flow passage for the flow of a first fluid; one or morefins thermally coupled and sandwiched by the spaced-apart plate pairsfor flow of a second fluid; a fluid manifold being fluidly coupled tothe spaced-apart plate pairs at a manifold end of the spaced-apart platepairs; and a tab extending from a flange end of a first plate of thefirst plate pair and being in contact with a second plate of a secondplate pair for providing a fluid flow blocker.
 18. The heat exchangeraccording to claim 17, wherein each plate of the first plate pair has atab extending from the plates and in contact with a plate of an adjacentplate pair.
 19. A heat exchanger assembly, comprising: a housing havinga cavity in communication with an opening; and a heat exchangerreceivable in the cavity of the housing, the heat exchanger comprising:a plurality of spaced-apart plate pairs, where each plate pair defines aflow passage for the flow of a first fluid; one or more fins thermallycoupled and sandwiched by the spaced-apart plate pairs for flow of asecond fluid; a fluid manifold being fluidly coupled to the spaced-apartplate pairs at a manifold end of the spaced-apart plate pairs; and a tabextending from a flange end of a first plate of the first plate pair andbeing in contact with a second plate of a second plate pair forproviding a fluid flow blocker.
 20. The heat exchanger assemblyaccording to claim 19, wherein each plate of the first plate pair has atab extending from the plates and in contact with a plate of an adjacentplate pair.